Process for forming floors



Dec. 28, 1954 J. BANNEYER PROCESS FOR FORMING FLOORS 3 Sheets-$heet 1 Filed May 26, 19 50 Kl l gaze 0% fig BY m ATTORNEYS.

Dec. 28, 1954 J. BANNEYER 2,597,864

PROCESS FOR FORMING FLOORS Filed May 26, 1950 s Sheets-Shet s .az INVENTOR.

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ATTORNEYS.

United States Patent PROCESS FOR FORMING FLOORS Joseph Banneyer, Chicago, Ill.

Application May 26, 1950, Serial No. 164,572

4 Claims. (Cl. 25-131) This invention relates to a floor-forming method and apparatus and is adapted for the forming of a foundation and floor simultaneously.

An object of the invention is to provide a floor and foundation-forming method and. means whereby this structure or structures may be formed in a minimum of time and at a minimum of expense. Yet another object is to provide in such a method a step and means for providing an air circulating space permitting the flow of air from the space below the floor upwardly through a wall structure and to the attic or top space of the structure. Yet another object is to utilize inexpensive means such as sand and the like for forming molds which provide reinforcing beams integral with the floor, while at the same time enabling the molding material to be readily removed after the completion of the floor and foundations, etc. Other specific objects and advantages will appear as the specification proceeds.

The invention is illustrated in a single embodiment, by the accompanying drawings, in which Fig. 1 is a broken perspective view of apparatus which may be employed in the practice of my invention and in the carrying-out of my new process; Fig. 2, a broken transverse sectional view of an edge portion of the floor after completion and of a portion of the wall above; Fig. 3, a broken sectional detail view of the form apparatus in position for forming a floor and wall adjacent one side of the building; Fig. 4, a view similar to Fig. 3 but showing sand or the like in position below and around the inner forms or beam-molds; Fig. 5, a view similar to Fig. 4 but showing reinforcing rods in the molded channel within the sand and after the removal of the beam-form apparatus; Fig. 6, a broken sectional view similar to Fig. 5 but showing the concrete after pouring; Fig. 7, a view similar to Fig. 6 but showing the sand or molding material removed; Fig. 8, a transverse sectional view, the

section being taken as indicated at line 8-8 of Fig. 7; Fig. 9, a broken sectional detail view showing a modified form of the invention in which the trough showing the placing of the beam or form directly upon sand and without the use of support apparatus; Fig. 10, a broken perspective view similar to Fig. 1 showing the sand or molding material in place with the beam-form removed preparatory to pouring the concrete; and Fig. 11, a sectional view taken on line 11-11 of Fig. showing the relationship of the archway to the molding material.

In the illustration given, I provide forms which illustrate apparatus that may be used in the new process. It is believed sufficient for the purposes herein to describe merely the apparatus used in .one corn er of a floor structure. As illustrated, I provide an outer form 10 having a curved corner portion 11. Spaced inwardly from the outer form 10 is an inner form 12. The form 12 is shorter than the outer form, as shown more clearly in Figs. 3 and 4. It is the purpose of the inner and outer forms to receive the poured concrete to form the foundation wall which supports the floor. If desired, a base slab or footing may be formed below the forms 10 and 12 and thereafter in the floor-forming operation concrete is poured to form the floor and also the foundation wall (between inner form 12 and outer form 10) simultaneously.

I desire to form the floor with reinforcing beams extending thereunder and I provide apparatus by which such beams may be formed integrally with the floor section. In the illustration given, I provide a base member 13 which may be formed of cast material such as concrete,

, 2,697,864 Patented Dec- 28, 1954 "ice etc. and which may be placed at any point within the structure to form an inner support. Preferably the top portion 14 of the base is enlarged and it may be preformed to receive and securely hold the inner ends of the beam-molds which will be described. The support may be formed of metal, concrete or any suitable material and may be fabricated to receive and be secured to the inner end of the beam-molds 15.

The beam-molds 15 may be of any suitable shape, length or curvature. In the illustration given, the beammolds 15 are trough-like in character and are substantially semicircular in cross section. If desired, the inner forms 12 may be recessed to receive the beam-molds 15 and the beam-molds may be equipped with laterally-extending brackets or flanges 16 by which they may be secured to the forms 12 throughthe use of bolts, screws, etc.

I prefer to secure the beam-molds 15 together in the desired arrangement and for this purpose connecting straps 17 may be used. In some instances, I prefer to have a beam-mold provided with a laterally-extending beam-mold 18 which extends at an acute angle from the first-mentioned mold. The molds 15 may be provided with horizontal straps 1-9 to which the connecting links 17 may be connected by bolts or other means.

I have found it highly advantageous to provide. a building wall above the floor which has a circulating space therethrough, and I desire to form in the floor an elongated slot communicating with the circulation space in the wall of the building. In the finished structure illustrated in Fig. 2, the floor 20 is provided with an air space 21 communicating with an air space 22 thereabove. In the specific structure shown, the wall is formed by the use of building blocks 23 and an inner wall formed of metal lath 24 and plaster 25 is spaced from the block wall 23 by the vertical air space 22. The air space 22 extends from the floor 20 to the attic and by providing the floor space or open area 21 air may circulate freely from the space below the floor through the air space 22, and thence, if desired, into and through the attic which may be provided with louvers or other control means. The entrance to the space below the floor may also be controlled by louvers or other means for controlling the circulation of the air.

In order to provide the space 21 in the floor, 1 provide a spaced channel-mold 26 which may be releasably secured by means of the screw or bolt 27 to the beammold 18 and which preferably lies along one side of the structure with the top of the mold 26 approximatelypflush with the top of the floor 20 after it is poured.

In order to provide an arch in the wall to permit the removal of sand, I provide in the outer form 10 spaced standards 28, as shown in Fig. 1, and between the arches extends a bottom wall 29. The arch members 28 are extended thereabove to provide a space for receiving conlc rete9 to form a bridge 30, as shown more clearly in Operation In the operation of the process and apparatus, the inner and outer forms 10 and 12 are placed into position and then the beam-forms are secured in position, as illustrated in Fig. l, with the inner ends of the long beammolds resting upon the support 13. Sand or other molding means is then introduced into the space below the beams 15. In many areas, it will be found that the depth of the space below the beams will be only a foot or so while in other cases the depth may be greater. In some instances the space may be only a few inches. event, it requires little expense and time to fill the space below the beams 15 and to bring the sand or other molding material around the beams and up to the level of the top of the beam-molds. If desired, sand which is treated or particularly good for molding purposes may be used in the area immediately around the molding beams 15. At the same time, I prefer to fill the space beammold 26 with sand.

It will be understood when it is desired to employ arches in the walls to permit removal of the sand after the hardening of the concrete that means should be provided for preventing the sand or molding material from receding through the arches. The obvious method to ac- In any oomplish this purpose is to provide a closure member 32 resting against the inner edges of arch members 28, as seen more clearly in Figs. and 11. However, it will be apparent that a closure member is not required, since the sand. itself can be used to. close the archway by piling it within. and around the exterior of the archway.

After the molding material has been tamped around the molding beams, the beam-molds may then be. removed, leaving the sand itself forming the mold-channels' there'below, as seen more clearly in Figs. 10 and. 11. The beam 26, which. is to form the space in the floor, is, however, separated from the beam-mold 18 and the member 26: is left in place supported by the sand therehelow and with the top of themember 2,6 flush with the topiof the floor which is to be poured.

I next pour the concrete to fill the spaces between the forms. 10 and 12 and also. to fill the mold impressions in the sand, while at. the same time forming the floor slab 2.0. After the concrete has set, the outer forms may be removed, and the standards 28 and wall 29 removed to expose the arch formed in the wall. The sand within the space below the floor may now be withdrawn through this arch. area. At the same time, the filled channel-form 26 may be lowered and removed and, in so doing, the space 21 is. formed in the floor wall.

The floor 20 may be thus formed with integral reinforcing beams 2'0 at any desired points, and I prefer to form a beam 20 adjacent the air space 21 so as to reinforce the floor at this point. It will be understood, however, that the reinforcing beams may be placed at any point desired and the air space also may be located. as desired so as to provide communication with the air space in the wall.

Upon the removal of the sand and molding material on the interior of the foundation walls, the inner forms 12 may be drawn through the archways in the walls and thus recovered for reuse. The inner supports 13 are preferably left in place and in supporting relation to the beams 20 of the floor.

It will be understood that any reinforcing means may be used in the making of the floor or walls. For example, a rod 31 may be supported in the mold area or impression 15 formed in the sand after the removal of the beam-mold or beam-form 15, as shown more clearly in Fig. 5. Any number of supporting rods, Wire or other means may be thus used for the strengthening of the beams, floor or walls.

The mold system above described is highly useful where the space ordinarily is not of suflicient height to remove the form after the concrete has been poured. It is also very economical since the making of the mold requires the use only of sand or other inexpensive materials, and these materials may be reused many times. With the structure shown, the air may be taken into the air space below the floor through louvers or screens set in the wall below the floor and these openings may be closed or opened according to the season of the year, or the air may be taken in through a common intake duct. In the latter case, the air may be controlled, heated, cooled or otherwise air-conditioned. From the air space beneath the floor, the air may circulate through the active air space 22 in the wall to the attic and through louvers n the room into the atmosphere, the circulation being increased if desired by the use of an exhaust fan in the roof.

In the modification shown in Fig. 9, the form or trough 15" is placed directly upon sand and the sand packed around the form to form the sand mold. While I have shown special forms, it will be understood that existing brick walls or any form of wall may be used instead of a form. Also, the inner and outer forms may be omitted, and a concrete block wall with openings for sand removal may be used with the beam forms to produce the sand molds. Thus when the concrete has set, it is necessary only toremove sand through the openings.

While in the foregoing specification I have set forth a specific structure in considerable detail for the purpose of illustrating one embodiment of the invention, it will be understood that such details of structure and method may be variedwidely by those skilled in the art without departing from the spirit of my invention.

I claim:

1. In a method of simultaneously forming in place a floor and a foundation wall, the steps comprising erecting vertically-extending inner and outer forms for the wall on the site of construction, both of said forms extending downwardly to the ground and said inner form terminating at a spaced distance below the top of said outer form, supporting horizontally-extending beam-forms upon the inner form, placing molding material about the beamforms to form a bed of said molding material with said beam-forms lying in recesses in the upper surface of said bed, removing thev beam-forms, and pouring concrete to fill the spaces between the inner and outer forms and the space above said molding material, including said recesses in the upper surface of said bed, to form an integral wall and. floor with. integral reinforcing beams extending along the. underside of the floor.

2. In a process for forming a floor and a supporting wall therefor, the steps of placing inner and outer vertically-extending. forms for the wall, placing a verticallyextending support On the inner side of said inner form, placing horizontally-extending beam-forms on said support and said inner form, filling the area around the beamforms with moi-d forming sand to form a bed of sand with said beam-forms lying in open recesses in the upper surface of said bed, removing the beam-forms and pouring concrete to fill the spaces between the inner and outer forms and thespace over said mold-forming sand, including said. recesses in the upper surface of said bed, whereby a concrete floor can be formed with integral reinforcing beams extending along its underside.

3. In a process for forming a floor and supporting wall, the steps of placing inner and outer vertically-extending forms in spaced relation for forming the wall, setting a central vertically-extending support on the inner side of the, inner form, placing horizontally-extending beamforms on the support and the, inner form, filling the area around, the beam-forms with mold-forming sand and partially covering said beam-forms to provide a bed of sand with said beam-forms lying in recesses in the upper surface. of said bed, supporting a beam-form along one side and filling the same with sand, removing all except the last-mentioned beam-form, pouring concrete between the inner and outer "forms and over the sand and into the recesses left. by the removing beam-forms, thereby forming a concrete floor with integral reinforcing beams extending along its underside, and subsequently removing said last-mentioned beam to form a space in said w-all.

4.v In a process for forming a floor and a supporting wall therefor, the steps of placing inner and outer vertically-extending forms in spaced relation, providing arch forms for forming -a hole in the finished wall, supporting vertically-extending beam-forms at the inner side of said inner form, packing molding sand, about said forms and partially covering said beam-forms to provide a bed of sand with said beam-forms lying in recesses in the upper surface of said bed, removing said beam-forms to uncover the recesses in said molding sand, pouring concrete into the space between said inner forms and over said, sand to fill the recesses therein, removing the outer form after the concrete is set, and then removing sand from the inner space through said hole in the cast wall whereby a concrete floor can be formed with integral reinforcing beams extending along its underside.

References. Cited in h file o thi Patent 

